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Mail Design Basics
for the Best Postal Rates and Service

 Letters - - - - - - - - - - - - - - - - - - - - - - - - --
Aspect Ratio: The Aspect Ratio (length divided by height) must be between 1.3 and 2.5.
Height: Between 3-1/2" and 6-1/8"
Length: Between 5" and 11-1/2"
Thickness: Minimum thickness .007" if less than 4-1/4" high and 6" long, or .009" if more than 4-1/4" high and 6" long.
Weight: Maximum: 3.4383 ounces for First Class; 3.3087 ounces for Regular Standard rate and 3.3388 ounces for Nonprofit rate. 

Folded self-mailer: Folded self-mailers should be prepared so that the fold is at the bottom and parallel with the longest edge of the mail piece. A tab closure is required at the center top. If folded with the fold at the top, two tabs must be placed at the bottom, 1" from each edge.  Though other folds may be allowed, they may require additional tabs. If 20-pound paper is used, 2 tabs are required to be placed 1" from each top edge.                

Booklet-Type Mail Piece:Two tabs are required on the top, unbound edge within 1" of either side edge.

                                                              

Other Considerations: Flexibility, rigidity, and mail piece color all effect the automation compatibility of every mail piece. Consult closely with your mail service or bulk mail acceptance unit.

Postcards - - - - - - - - - - - - - - - - - - - - - - - - -
Aspect Ratio: Must be between 1.3 and 2.5
Minimum size: 3-1/2" high, 5" long, .007" thick
Maximum size: 4-1/4" high, 6" long, .016" thick
Paper Color: Any light color, not brilliant colors
Paper Weight: Not less than 75 pound paper

IMPORTANT NOTE:
If cards are designed with a message on the left side of the address panel, postal regulations require 2-1/8" for addressing -- HOWEVER, a barcode measures 3-1/8" and requires placement 1/2" from the rightmost edge.  Add another 1/8" clearance on the left side of the barcode and you need a total of 3-3/4" clear space for addressing with barcodes.

Flats - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

For flats prepared as single sheets or in envelopes, the "length" is the longest dimension, the "height" is perpendicular to the length.

For flats with a bound or folded edge, the height is the dimension parallel to the bound or folded edge. The length is perpendicular to the height.

If a flat is folded more than once or bound and then folded, the height is based on the final fold. These pieces must be designed so the address is in view when the final folded edge is to the right and any intermediate bound or folded edge is at the bottom.

Flats must be rectangular, never square.
Height: Between 4" and 12"
Length: Between 4" and 15 3/4"
Weight Max: 13 ounces for First Class; 6 lbs. (non-automation), 16 oz. (automation) for Periodicals; or 16 oz. for Standard Mail rates.
Thickness: minimum: 1/4 inch.
                    maximum: 3/4 inch.